Shipping container

ABSTRACT

One aspect of the present invention provides an insert for receiving and securely retaining an article. The insert includes a base section, a lid section and a ribbed hinge section that couples the base section with the lid section. The base section receives the article and includes a plurality of corners. The base section includes a plurality of elevated portions and a recessed portion. The plurality of elevated portions are positioned adjacent to the plurality of corners of the base section, and each of the plurality of elevated portions include a locking mechanism that are configured to selectively couple the lid section to the base section to retain the article between the base section and the lid section.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application claims the benefit of U.S. Provisional Patent Application No. 60/783,702, filed on Mar. 17, 2006.

BACKGROUND OF THE INVENTION

1. Field of the Invention

The present invention relates generally to shipping containers for receiving and securely retaining at least one article, and more particularly to shipping containers having inserts to be used for receiving and securely retaining digital media.

2. State of the Art

Paperboard containers used for shipping and securely retaining articles are known. U.S. Pat. No. 6,705,469 (the '469 patent) discloses a shipping container having a shell formed from a paper pulp composition as an elongate one-piece contoured shell having integral hinge areas which enable the end sections of the shell to be folded up and over the central shell section to enclose the shell and to engage and hold a product engaged and held on the central shell section. Additionally, the insert or shell disclosed in the '469 patent is molded from a sheet or web of paper pulp, in the same manner as conventional egg containers. Because the container disclosed in the '469 patent is molded, it is expensive to produce. Additionally, the ridged construction and contours of the container require that much space is provided for storage of the container.

What is needed in the art is a shipping container for receiving and securely retaining an article that is relatively inexpensive to produce.

Additionally, what is needed in the art is a shipping container for receiving and securely retaining an article that is simple to assemble, and collapsible to thereby minimize space required for storage before and after assembly.

SUMMARY OF THE INVENTION

The present invention provides a shipping container for receiving and securely retaining articles. Furthermore, the present invention provides a shipping container that is relatively inexpensive to produce. Furthermore still, the present invention provides a shipping container that is easy to assemble and collapsible to thereby minimize the space required for storage before and after assembly.

A particular aspect of the present invention provides a shipping container for receiving and securely retaining at least one article. The shipping container includes an insert comprising a single paperboard sheet having a plurality of folds, at least one locking mechanism, and at least one pair of opposing slots formed in the paperboard sheet, wherein the opposing slots are adapted to receive and retain at least one article. The shipping container further includes a paperboard box adapted to receive the insert.

An additional aspect of the present invention provides a shipping container for receiving and securely retaining five articles. The shipping container includes an insert comprising a single paperboard sheet having a plurality of folds, at least one locking mechanism, and five pair of opposing slots formed in the paperboard sheet, wherein the opposing slots are adapted to receive and retain the five articles. The shipping container further includes a paperboard box adapted to receive the insert.

An additional aspect of the present invention provides a shipping container for receiving and securely retaining ten articles. The shipping container includes an insert comprising a single paperboard sheet having a plurality of folds, at least one locking mechanism, and ten pair of opposing slots formed in the paperboard sheet, wherein the opposing slots are adapted to receive and retain the ten articles. The shipping container further includes a paperboard box adapted to receive the inset.

The present invention also provides a method of forming an insert from a single paperboard sheet, said paperboard sheet having a plurality of folds, at least one locking mechanism, and at least one pair of opposing slots formed therein adapted to receive and retain said at least one article comprising the steps of: folding said single paperboard sheet starting from the outside edges; engaging the locking mechanism or tabs into a locked position; loading at least one article into a first slot of said at least one pair of slots on a first receiving side; folding a second receiving side over said first receiving side thereby inserting said at least one article into a second slot of said at least one pair of slots thereby forming the insert;.

An additional aspect of the present invention comprises an insert having a casing constructed of a plastic material that serves to secure a single article. The insert further comprises a base section for receiving an article, a lid section, and a ribbed hinge section coupling the base section to the lid section. The base section includes a plurality of elevated portions and a recessed portion. The elevated portions are situated along the four corners of the substantially square base section, wherein each of the elevated portions includes a locking tab that serves as a locking mechanism. The tab of the elevated portion is aligned to engage a slot formed in the lid section. In operation, the tab of the elevated portion is inserted into the aforementioned slot to selectively lock the lid section to the base section, thereby securing the article within a cavity formed in the insert. Additionally, the elevated portions of the base section further comprise inner walls that serve to engage the article to thereby limit lateral movement of the article within the insert. An additional aspect of this embodiment includes at least one damping protrusion that projects outward from the inner surface of the lid section. When the lid section and the base section are secured in the locked position, the damping protrusion is in abutting engagement with the stored article thereby serving as a damper or shock absorber.

BRIEF DESCRIPTION OF THE DRAWINGS

The above-mentioned and other features and advantages of this invention, and the manner of attaining them, will become appreciated and be more readily understood by reference to the following detailed description of the invention in conjunction with the accompanying drawings, wherein:

FIGS. 1-5 provide a series of perspective views of a five pack data courier of the present invention.

FIGS. 6-9 provide a series of perspective views of the five pack data courier and an assembled outside container for receiving the five pack data courier.

FIG. 10 a is a drawing of an unassembled ten pack data courier insert of a particular aspect of the present invention.

FIG. 10 b is a drawing of an unassembled five pack data courier insert of a particular aspect of the present invention.

FIG. 10 c is a drawing of an unassembled outside container for receiving the ten pack data courier insert shown in FIG. 10 a.

FIG. 10 d is a drawing of an unassembled outside container for receiving the five pack data courier insert shown in FIG. 10 b.

FIGS. 11-14 provide a series of views of a one piece data courier of the present invention.

FIGS. 15-18 provide a series of views of one alternative embodiment of the insert shown in FIGS. 11-14.

FIG. 19 is a drawing of an unassembled outside container for receiving the insert shown in FIGS. 11-14 or the insert shown in FIGS. 15-18.

FIG. 20 is a drawing of an unassembled outside container for receiving five of the inserts shown in FIGS. 11-14, five of the inserts shown in FIGS. 15-18, or any combination thereof.

FIG. 21 is a drawing of an unassembled outside container for receiving ten of the inserts shown in FIGS. 11-14, ten of the inserts shown in FIGS. 15-18, or any combination thereof.

DETAILED DESCRIPTION OF THE INVENTION

Referring now to the drawings and particularly FIGS. 1-8, a series of elevated views of the five pack data courier insert 100 are shown. The five pack data courier insert 100 comprises an upper side 102 and a lower side 104 and a plurality of creases or folds 106 to thereby serve as guides in forming the assembled insert. Additionally, the five pack data courier insert 100 comprises a locking mechanism including a plurality of locking slots 108 and a plurality of locking tabs 110, wherein said locking slots 108 and locking tabs 110 are aligned to retain the insert 100 in assembled form. In the illustrated embodiment four pair of locking slots 108 and two pair of locking tabs 110 are used, however additional aspects having other configurations are considered within the scope of the invention. In the illustrated embodiment, the locking slots 108 are comprised of three walls, including two sidewalls 112 and a base wall 114, wherein the side wall and base wall intersect at a point to thereby form an obtuse angle. Furthermore, locking tabs 110 include an outer edge 116 and two side edges 118 wherein the side edge and the outer edge intersect to form an acute angle. This unique configuration allows the insert to be locked into an assembled form as illustrated in FIG. 3.

The five pack data courier insert 100 further includes five pair of rectangular slots or bores 120 defined therein, which shall serve to receive and retain one or more articles 134 or data tapes when the insert 100 is assembled. It will be understood that slots 120 may be substantially rectangular, circular, or any other desired shape to substantially match the shape of the article to be secured by insert 100. The five slots 120 include two outer slots, a center slot, and two additional slots positioned therebetween. The two outer slots each comprise a single support tab 122, and the center slot comprises a pair of opposing support tabs 122 as illustrated in detail in FIG. 2.

Referring now to FIG. 3 an elevated view of the assembled insert 100 is shown. The assembled insert 100 comprises an upper receiving portion 124, a lower receiving portion 126, and a support base 128. In order to form upper receiving portion 124 of the insert 100 shown in FIG. 3, as best seen in FIG. 2, outside edge 129 is folded inwardly along folds 106 a so that the outer locking slots 108 a are positioned adjacent to inner locking slots 108 b. Thereafter, the locking slots 108 a, 108 b are positioned adjacent to tabs 110 by folding the paperboard sheet along folds 106 b. As illustrated in FIG. 3, the insert 100 is then locked into form by inserting the locking tabs 10 into the adjacent locking slots 108. The lower receiving portion 126 is locked into position in the same fashion as upper receiving portion 124. With the device locked into form, articles such as digital tapes 134 (FIG. 4), may be inserted into the rectangular slots 120 of the lower receiving portion 126. As best seen in FIG. 4, the upper receiving portion 124 and lower receiving portion 126 both include multiple layers, and particularly an upper layer 132 and central or base layer 130. The support tabs 122 extend inwardly toward one another from the edges of slots 120 and serve to form side walls when bent relative to upper layer 132, thereby providing an additional support member between the upper layer 132 of the lower article receptacle and the base layer 130 of the lower article receptacle. While the illustrated insert 100 is described as having a particular number of support tabs 122 or sidewalls as described above, additional aspects are contemplated wherein each rectangular slot 120 includes two opposing support tabs 122. After one end of the articles 134 are placed into the rectangular slots 120 of the lower receiving portion 126, the rectangular slots 120 of the upper receiving portion 124 are positioned to receive the opposite end of the articles 134 as illustrated in FIGS. 5 and 6, thereby securely retaining the articles 134 within the insert 100.

Referring now to FIGS. 6 and 7, the five pack data courier insert 100 with the articles 134 secured within is shown. With the upper receiving portion 124 placed upon the top of the articles 134, the insert 100 may be received within an outside container 136, such as a paperboard box. Referring now to FIGS. 8 and 9, the outside container 136 is sealed to securely retain insert 100 by closing the flaps 138 and applying a tamper evident security seal 140.

While the detailed description above describes a five pack data courier, an additional embodiment directed to a ten pack data courier is disclosed. Referring now to FIG. 10 a, an elevated view of an unassembled ten pack data courier insert 150 is shown, including ten pair of opposing rectangular slots 152. The ten pack data courier 150 is assembled utilizing the principles described in the assembly of the five pack data courier above. While the illustrated insert 150 includes a pair of support tabs 154 in each slot 152, additional inserts wherein the slots include no tabs or one tab are within the scope of the invention.

As best seen in FIG. 10 b, an elevated view of an unassembled five pack data courier insert 160 is shown, including five pair of opposing rectangular slots 162. The five pack data courier 160 is assembled utilizing the priciples described above and illustrated in FIGS. 1-9. While the illustrated insert 160 in FIG. 10 b includes a pair of support tabs 164 in each slot 162, additional inserts such as the one illustrated in FIGS. 1-9 wherein the slots include no tabs or one tab are within the scope of the invention.

As best seen in FIG. 10 c, a unassembled outside container 135 for receiving the ten pack data courier insert, and FIG. 10 d is an unassembled outside container for receiving the five pack data courier insert of the present invention shown in FIGS. 6-9.

Referring now to FIGS. 11-14, an insert or data tape courier 200 including a casing that may be constructed of a thermally molded plastic material that serves to secure a single article is shown. It will be understood that the article that is secured within insert 200 may be a data cartridge, such as, but not limited to, a LTO Ultrium data cartridge, a DLT® data cartridge, a 3592 data cartridge, and a 3590 data cartridge. The insert 200 further comprises a base section 202 for receiving the article, a ribbed hinge section 204, and a lid section 206. The base section includes a plurality of elevated portions 208 and a recessed portion 210. The plurality of elevated portions 208 are situated along the four corners of the substantially square base section 202 and may be in contact with the article. Elevated portions 208 may be generally L-shaped and include a top wall that is configured to be positioned adjacent to an inner surface 220 of lid section 206 when the insert 200 is in a closed position. Further, each of said elevated portions 208 includes a locking tab or protrusion 212 that extend outwardly from the top wall of the elevated portions 208 and serves as a locking mechanism for selectively retaining the insert 200 in the closed position. The locking tab 212 of the elevated portion is aligned to engage a slot or bore 214 formed in the lid section 206.

In the alternative, as best seen in FIGS. 15-18, it will be understood that the lid section 206 may include one or more locking tabs or protrusions 212′ that extend outwardly from the top wall of the lid section 206, which serve as a locking mechanism for selectively retaining the insert 200′ in the closed position. The one or more locking tabs 212′ of the lid section 206 are aligned to engage a slot or bore 214′ formed in the elevated portions 208 of the base section 202.

In operation, with reference to FIGS. 11-14, the locking tab 212 of the elevated portion 208 is inserted into the aforementioned slot 214 to selectively lock the lid section 206 to the base section 202, thereby securing the article (not shown) within a cavity 217 defined by the elevated portions 208 formed in the insert 200. Additionally, the elevated portions 208 of the base section further comprise inner walls 216 that serve to engage the article to thereby limit lateral movement of the article within the cavity 217 of insert 200. An additional aspect of this embodiment includes at least one damping protrusion 218 projecting outward from the inner surface 220 of the lid section 206. The damping protrusion 218 may comprise a substantially rectangular protuberance projecting outward from the inner surface of the lid section 206. When the lid section 206 and the base section 202 are in the locked position, the damping protrusion 218 engages the stored article, thereby serving as a damper or shock absorber further protecting the article during shipping. When not in use, a plurality of inserts may be stacked on top of one another when in the opened position (FIGS. 12 and 13) for easy storage and handling. The insert 200′ shown in FIGS. 15-18 may be operated in a similar fashion.

FIG. 19 is a drawing of an unassembled outside container or shipping box 222 for receiving insert 200 shown in FIGS. 11-14, or insert 200′ shown in FIGS. 15-18. Container 222′, 222″ may also be configured to hold, for example, five inserts as best seen in FIG. 20, ten inserts as best seen in FIG. 21, or fifty inserts. All of the inserts being held by the containers 222′, 222″ may either be of the configuration shown in FIGS. 11-14 or in the configuration shown in FIGS. 15-18. It will be understood that containers 222′, 222″ may hold different combination of the inserts shown in FIGS. 11-18, for example, container 222′ may be configured to hold two of inserts 200 and three of inserts 200′. Other types of inserts that fall within the scope of the present invention may also be held my containers 222, 222′, 222″. It will also be understood that container 222, 222′, 222″ may include a tamper evident security seal 140 (FIG. 9) and a moisture resistant sleeve.

The embodiments described are chosen to provide an illustration of principles of the invention and its practical application to enable thereby one of ordinary skill in the art to utilize the invention in various embodiments and with various modifications as are suited to the particular use contemplated. Therefore, the foregoing description is to be considered exemplary, rather than limiting, and the true scope of the invention is that described in the following claims. 

1. A shipping container for receiving and securely retaining at least one article comprising: an insert comprising a single paperboard sheet; said insert further comprising a plurality of folds, at least one locking mechanism, and at least one pair of opposing bores defined therein adapted to receive and retain said at least one article; and a paperboard box adapted to receive and securely retain said insert.
 2. A method of forming an insert from a single paperboard sheet, said paperboard sheet having a plurality of folds, at least one locking mechanism, and at least one pair of opposing bores defined therein adapted to receive and retain said at least one article comprising the steps of: folding said single paperboard sheet in starting from the outside edges; engaging the locking mechanism into a locked position; loading said at least one article into a first bore of said at least one pair of bores on a first receiving side; and folding a second receiving side over said first receiving side thereby inserting said at least one article into a second bore of said at least one pair of bores thereby forming said insert.
 3. An insert for receiving and securely retaining an article, the insert comprising: a base section for receiving the article, said base section including a plurality of corners; a lid section; and a ribbed hinge section coupling said base section with said lid section, wherein said base section includes a plurality of elevated portions and a recessed portion, wherein said plurality of elevated portions are positioned adjacent to said plurality of corners of said base section, and wherein each of said plurality of elevated portions include a locking mechanism that are configured to selectively couple said lid section to said base section to retain the article between said base section and said lid section.
 4. The insert for receiving and securely retaining an article of claim 3 wherein said locking mechanism comprises: a locking tab extending outwardly from at least one of said plurality of elevated portions; and a slot formed in said lid section, wherein said locking tab is configured to be selectively positioned within said slot.
 5. The insert for receiving and securely retaining an article of claim 4 wherein said locking tab extends outwardly from a top wall of said plurality of elevated portions.
 6. The insert for receiving and securely retaining an article of claim 3 wherein each of said plurality of elevated portions include inner walls that are configured to engage the article to limit lateral movement of the article within said base section.
 7. The insert for receiving and securely retaining an article of claim 3 further comprising at least one damping protrusion projecting outwardly from an inner surface of said lid section, wherein said at least one damping protrusion engages the article when said lid section and said base section are in a locked position.
 8. The insert for receiving and securely retaining an article of claim 3 wherein the article is a data cartridge.
 9. The article for receiving and securely retaining an article of claim 8 wherein said data cartridge is at least one of a LTO Ultrium data cartridge, a DLT® data cartridge, a 3592 data cartridge, and a 3590 data cartridge.
 10. The insert for receiving and securely retaining an article of claim 3 wherein at least one of said base section, said lid section, and said hinge section is formed of a thermally molded plastic material.
 11. The insert for receiving and securely retaining an article of claim 3 wherein at least one of said plurality of elevated portions are L-shaped.
 12. The insert for receiving and securely retaining an article of claim 3 wherein said base section includes four corners.
 13. An insert for receiving and securely retaining an article, the insert comprising: a base section for receiving the article, said base section including a plurality of corners; a lid section; a ribbed hinge section coupling said base section with said lid section; and locking means for selectively coupling said lid section to said base section to retain the article between said base section and said lid section, wherein said base section includes a plurality of elevated portions and a recessed portion, wherein said plurality of elevated portions are positioned adjacent to said plurality corners of said base section and are in contact with the article.
 14. The insert for receiving and securely retaining an article of claim 13 wherein each of said plurality of elevated portions include inner walls that are configured to engage the article to limit lateral movement of the article within said base section.
 15. The insert for receiving and securely retaining an article of claim 13 further comprising damping means that engages the article when said lid section and said base section are in a locked position.
 16. The insert for receiving and securely retaining an article of claim 13 wherein the article is a data cartridge.
 17. The article for receiving and securely retaining an article of claim 16 wherein said data cartridge is at least one of a LTO Ultrium data cartridge, a DLT® data cartridge, a 3592 data cartridge, and a 3590 data cartridge.
 18. The insert for receiving and securely retaining an article of claim 13 wherein at least one of said base section, said lid section, and said hinge section is formed of a thermally molded plastic material.
 19. The insert for receiving and securely retaining an article of claim 13 wherein said base section includes four corners.
 20. A method of packaging an article for shipping, the method comprising: providing a base section including a plurality of elevated portions and a recessed portion, wherein said plurality of elevated portions are positioned adjacent to a plurality of corners of said base section, and wherein a locking tab extends outwardly from at least one of said plurality of elevated portions; providing a lid section coupled with said base section by a ribbed hinge section, wherein a slot is formed in said lid section; inserting an article with said recessed position so that the article is in contact with said plurality of elevated portions; and selectively engaging said locking tab within said slot so that the article is securely positioned between said base section and said lid section.
 21. The method of packaging an article for shipping of claim 20 wherein each of said plurality of elevated portions include inner walls that engage the article to limit lateral movement of the article within said base section.
 22. The method of packaging an article for shipping of claim 20 further comprising providing at least one damping protrusion projecting outwardly from an inner surface of said lid section, wherein said at least one damping protrusion engages the article when said lid section and said base section are selectively engaged.
 23. The method of packaging an article for shipping of claim 20 wherein said base section, said lid section, and said hinge section form an insert, and wherein said insert and said article contained within said insert are positioned within a shipping container.
 24. The method of packaging an article for shipping of claim 23 wherein said shipping container includes a tamper evident security seal.
 25. The method of packaging an article for shipping of claim 23 wherein said shipping container is configured to hold at least five inserts. 